Process for oxidizing alkyl aromatic compounds

ABSTRACT

A process for oxidizing an alkyl-aromatic compound is described. The process includes contacting the alkyl-aromatic compound, a solvent comprising an ionic liquid, a bromine source, a catalyst, and an oxidizing agent in a first reaction zone to produce a first product comprising a first mother liquor and at least one of an aromatic alcohol, an aromatic aldehyde, an aromatic ketone, and an aromatic carboxylic acid.

STATEMENT OF RELATED CASES

This application is a continuation-in-part of U.S. application Ser. No.13/155,519, filed Jun. 8, 2011, entitled Process for Oxidizing AlkylAromatic Compounds, which claims the benefit of U.S. ProvisionalApplication No. 61/360,153 which was filed on Jun. 30, 2010.

FIELD OF THE INVENTION

This invention relates to processes useful for oxidizing alkyl aromaticcompounds. More particularly, the invention relates to the oxidation ofalkyl aromatic compounds using ionic liquid.

BACKGROUND OF THE INVENTION

Oxidation of alkyl aromatic compounds, e.g., toluene and xylenes areimportant commercial processes. A variety of oxidation products may beobtained including aromatic carboxylic acids such as terephthalic acid(1,4-benzenedicarboxylic acid) and isophthalic acid(1,3-benzenedicarboxylic acid) which are used, for example, in thepolymer industry.

It is known that oxidation products, such as aromatic alcohols, aromaticaldehydes, aromatic ketones, and aromatic carboxylic acids, may solidifyor crystallize at oxidation conditions and/or as the reaction mixturecools. Thus, mixtures of oxidation products may be produced whichrequire further processing to increase the purity of the desiredproduct. For example, in the production of terephthalic acid, theoxidation product is often referred to as crude terephthalic acidbecause it contains impurities including color bodies and intermediateoxidation products, especially 4-carboxybenzaldehyde (4-CBA). To obtainpolymer grade or purified terephthalic acid, various purification stepsare known in the art including: washing the crude terephthalic acid withwater and/or a solvent, additional oxidation or crystallization steps,and reacting a solution of dissolved crude terephthalic acid withhydrogen at hydrogenation conditions usually including a catalystcomprising palladium and carbon. Often several purification steps areused.

U.S. Pat. No. 2,833,816 discloses processes for oxidizing aromaticcompounds to the corresponding aromatic carboxylic acids. A process forthe liquid phase oxidation of alkyl aromatic compounds uses molecularoxygen, a metal or metal ions, and bromine or bromide ions in thepresence of an acid. The metals may include cobalt and/or manganese.Exemplary acids are lower aliphatic mono carboxylic acids containing 1to 8 carbon atoms, especially acetic acid.

U.S. Pat. No. 6,355,835 discloses a process for the preparation ofbenzene dicarboxylic acids by liquid phase oxidation of xylene isomersusing oxygen or air by oxidizing in the presence of acetic acid as asolvent, a cobalt salt as a catalyst, and an initiator. The oxidationstep is followed by flashing the reaction mixture to remove volatilesubstances and cooling and filtering the material to get crude benzenedi-carboxylic acid as a solid product and a filtrate. Recrystallizingthe crude benzene di-carboxylic acid to obtain at least 99% purity andrecycling of the filtrate are also disclosed.

U.S. Pat. No. 7,094,925 discloses a process for preparing analkyl-aromatic compound. The process includes mixing an oxidizing agentor sulfur compound in the presence of an ionic liquid. Air, dioxygen,peroxide, superoxide, or any other form of active oxygen, nitrite,nitrate, and nitric acid or other oxides or oxyhalides of nitrogen(hydrate or anhydrous) can be used as the oxidizing agent. The processis typically carried out under Bronstead acidic conditions. Theoxidation is preferably performed in an ionic liquid containing an acidpromoter, such as methanesulfonic acid. The product is preferably acarboxylic acid or ketone or intermediate compound in the oxidation,such as an aldehyde, or alcohol.

U.S. Pat. No. 7,985,875 describes a process for preparing an aromaticpolycarboxylic acid by liquid phase oxidation of a di- ortri-substituted benzene or naphthalene compound. The process involvescontacting the aromatic compound with an oxidant in the presence of acarboxylic acid solvent, a metal catalyst, and a promoter in a reactionzone. The promoter is an ionic liquid comprising an organic cation and abromide or iodide anion. The promoter is used in a concentration rangeof about 10 to about 50,000 ppm (based on solvent) with a preferredrange of 10-1,000 ppm. No other promoters, such as bromine-containingcompounds, need to be used in the process. The process produces crudeterephthalic acid (CTA) having 1.4-2.2% 4-CBA. Purification of the CTAis required to obtain purified terephthalic acid (PTA).

US 2010/0174111 describes a process for purifying aryl carboxylic acids,such as terephthalic acid. The impure acid is dissolved or dispersed inan ionic liquid. A non-solvent (defined as a molecular solvent for whichthe ionic solvent has high solubility and for which the aryl carboxylicacid has little or no solubility) is added to the solution toprecipitate the purified acid.

U.S. Pat. No. 7,692,036, 2007/0155985, 2007/0208193, and 2010/0200804disclose a process and apparatus for carrying out the liquid-phaseoxidation of an oxidizable compound. The liquid phase oxidation iscarried out in a bubble column reactor that provides for a highlyefficient reaction at relatively low temperatures. When the oxidizedcompound is para-xylene, the product from the oxidation reaction is CTAwhich must be purified. Purification is said to be easier than forconventional high temperature processes.

SUMMARY OF THE INVENTION

One aspect of the invention is a process for oxidizing an alkyl-aromaticcompound. In one embodiment, the process includes contacting thealkyl-aromatic compound, a solvent comprising an ionic liquid, a brominesource, a catalyst, and an oxidizing agent in a first reaction zone toproduce a first product comprising a first mother liquor and at leastone of an aromatic alcohol, an aromatic aldehyde, an aromatic ketone,and an aromatic carboxylic acid.

BRIEF DESCRIPTION OF THE DRAWING

The FIGURE is a general process flow diagram for one embodiment of aprocess for producing oxidized alkyl aromatic compounds.

DETAILED DESCRIPTION OF THE INVENTION

The process involves oxidizing an alkyl-aromatic compound to produceoxidized alkyl aromatic compounds. The process involves contacting thealkyl-aromatic compound, a solvent comprising an ionic liquid, a brominesource, a catalyst, and an oxidizing agent in a first reactor to producea first product comprising a first mother liquor and at least one of anaromatic alcohol, an aromatic aldehyde, an aromatic ketone, and anaromatic carboxylic acid.

Optionally, one or more additional oxidation steps can be included. Theadditional oxidation steps comprise contacting at least a portion of thefirst product, a second solvent comprising a second ionic liquid, asecond bromine source, a second catalyst, and a second oxidizing agentin a second reactor to produce a second product comprising a secondmother liquor and at least one of the aromatic alcohol, the aromaticaldehyde, the aromatic ketone, and the aromatic carboxylic acid.

Optionally, the mother liquor from the first reactor can be recycled tothe first reactor and/or the mother liquor from the second reactor canbe recycled to the first or second reactor. Because of the low vaporpressure of ionic liquids, it is likely there will be low volatilitylosses, and the ionic liquid will remain in the mother liquor forrecycle. Furthermore, ionic liquids can have low decomposition levels,minimal loss is expected during use. Thus, high levels of recycle can beobtained.

The contacting step(s) may be practiced in laboratory scale experimentsthrough full scale commercial operations. The process may be operated inbatch, continuous, or semi-continuous mode. The contacting step can takeplace in various ways. The order of addition of the components (e.g.,alkyl-aromatic compound, solvent, bromine source, catalyst, andoxidizing agent) is not critical. For example, the components can beadded individually, or two or more components may be combined or mixedbefore being combined or mixed with other components.

The Figure is a general process flow diagram for an embodiment of aprocess 100 for producing purified oxidized alkyl aromatic compounds.

The feed 105 is introduced into oxidation zone 110 along with anoxidizing agent 115. An overhead condenser (not shown) can remove heatfrom the reflux stream to control reaction zone temperature.

Effluent liquid 120 from the oxidation zone 110 is sent to an optionalsecond oxidation zone 125 where a second oxidant 130 is added tocomplete the oxidation process. The second oxidation zone 125 can alsoact as a crystallization zone.

Two oxidation zones are shown in the Figure. The two oxidation zones canhave different solvents and different catalyst compositions, if desired.The reaction zones can include different types of reactors, withdifferent residence times and different operating conditions, ifdesired.

The effluent 135 from the second oxidation zone 125 is sent tocrystallization zone 140. Crystallization zone 140 can include one ormore post reaction zones and/or one or more crystallizers. If a postreaction zone is needed to increase conversion further, additionaloxidizing agent will be required. The post reaction zone can operate atlower pressure and lower temperature to help with crystallization. Oneor more crystallizers are used to complete the crystallization of theproduct, such as terephthalic acid at lower temperatures. Care should betaken not to co-crystallize impurities. The solvent comprising ionicliquids provides a medium where the impurities and/or intermediatesremain in the solvent or are further oxidized to terephthalic acid,thereby substantially reducing the co-crystallized impurities. Eachcrystallizer can have different solvent compositions to reduceimpurities, if desired.

The crystallized product is separated from the solvent in a separatorzone 145. The separator zone 145 can include one or more of filters,centrifuges, and dryers, as is known in the art.

Solvent 150 is used to wash the product crystals in the separator zone145. The purified product 150 is dried and stored in a product silo. Anadditional separation device may be needed to ensure that the productmeets the product specification before storage.

The washed mother liquor 155 is divided with a portion 160 beingrecycled to the first oxidation zone 110 and/or the second oxidationzone 125. Another portion 165 can be sent to regeneration zone 170,where catalyst and solvent is separated and regenerated. Make-up solvent185 can be added to the recycle portion 160 as needed.

Suitable alkyl aromatic compounds or feeds to be oxidized includearomatic compounds comprising at least one benzene ring having at leastone alkyl group. Methyl, ethyl, and isopropyl alkyl groups are preferredalkyl groups, although other alkyl groups can be used if desired. In anembodiment, the alkyl aromatic compound is selected from toluene,para-xylene, ortho-xylene, and meta-xylene. The feed may comprise morethan one alkyl aromatic compound. As the oxidation reaction generallyproceeds through successive degrees of oxidization, suitable feedcompounds also include partially oxidized intermediates relative to thedesired oxidized product. For example, in the production of terephthalicacid, the alkyl aromatic feed may comprise para-toluic acid and/or4-carboxybenzaldehyde (4-CBA).

The solvent comprises at least one ionic liquid. Two or more ionicliquids can be used, if desired.

Generally, ionic liquids are non-aqueous, organic salts composed of ionswhere the positive ion is charge balanced with a negative ion. Thesematerials have low melting points, often below 100° C., undetectablevapor pressure, and good chemical and thermal stability. The cationiccharge of the salt is localized over hetero atoms, and the anions may beany inorganic, organic, or organometallic species.

Most ionic liquids are formed from cations that do not contain acidicprotons. The synthesis of ionic liquids can generally be split into twoparts: formation of the desired cation, and anion exchange to form thedesired product. Quaternization of an amine or phosphine, for example,is the initial step in the synthesis of the cation of an ionic liquid.If it is not possible to form the desired anion directly by thequaternization reaction, a further step is required.

There are estimated to be hundreds of thousands of simple ioncombinations to make ionic liquids, and an almost endless (10¹⁸) numberof potential ionic liquid mixtures. This implies that it should bepossible to design an ionic liquid with the desired properties to suit aparticular application by selecting anions, cations, and mixtureconcentrations. Ionic liquids can be adjusted or tuned to provide aspecific melting point, viscosity, density, hydrophobicity, miscibility,etc. for specific applications. The thermodynamics and reaction kineticsof processes carried out in ionic liquids are different from those inconventional media. This creates new opportunities for catalyticreactions, separations, combined reaction/separation processes, heattransfer agents, hydraulic fluids, paint additives, electrochemistryapplications, as well as many others. Ionic liquids do not emit volatileorganic compounds (VOCs), providing a basis for clean manufacturing,e.g., “green chemistry.”

Cations and anions for ionic liquids are described in US Publication2010/0174111, for example.

The organic cation can comprise a linear, branched, or cyclicheteroalkyl unit. The term “heteroalkyl” refers to a cation comprisingone or more heteroatoms chosen from nitrogen, oxygen, sulfur, boron,arsenic, boron, antimony, aluminum, or phosphorous capable of forming acation. The heteroatom can be a part of a ring formed with one or moreother heteroatoms, for example, pyridinyl, imidazolinyl rings, that canhave substituted or unsubstituted linear or branched alkyl unitsattached thereto. In addition, the cation can be a single heteroatomwherein a sufficient number of substituted or unsubstituted linear orbranched alkyl units are attached to the heteroatom such that a cationis formed.

Non-limiting examples of heterocyclic and heteroaryl units that can bealkylated to form cationic units include imidazole, pyrazoles,thiazoles, isothiazoles, azathiozoles, oxothiazoles, oxazines,oxazolines, oxazaboroles, dithiozoles, triazoles, selenozoles,oxaphospholes, pyrroles, boroles, furans, thiphenes, phospholes,pentazoles, indoles, indolines, oxazoles, isothirazoles, tetrazoles,benzofuran, dibenzofurans, benzothiophenes, dibenzothoiphenes,thiadiazoles, pyrdines, pyrimidines, pyrazines, pyridazines,piperazines, piperidines, morpholines, pyrans, annolines, phthalazines,quinazolines, and quinoxalines.

The anionic portion of the ionic liquid can comprise an inorganic,organic, or organometallic moiety. Non-limiting examples of anionsinclude inorganic anions: halogens, (e.g., F, Cl, Br, and I); borides,BX₄, wherein X represents halogen, (e.g., BF₄, BCl₄), and the like;phosphates(V), PX₆; PF₆, and the like; arsenate(V), AsX₆; AsF₆, and thelike; stibate(V) (antimony), SbX₆; SbF₆, and the like; CO₃ ²⁻; NO₂ ¹⁻,NO₃ ¹⁻, SO₄ ²⁻, PO₄ ³⁻, (CF₃)SO₃ ¹⁻, and combinations and derivativesthereof.

Other non-limiting examples of ionic liquid anions include substitutedazolates, that is, five membered heterocyclic aromatic rings that havenitrogen atoms in either positions 1 and 3 (imidazolates); 1, 2, and 3(1,2,3-triazolates); or 1, 2, 4 (1,2,4-triazolate). Substitutions to thering occur at positions that are not located in nitrogen positions(these are carbon positions) and include CN (cyano-), NO₂ (nitro-), andNH₂ (amino) group appended to the heterocyclic azolate core.

Further non-limiting examples of anions include substituted orunsubstituted borides: B(R)₄; substituted or unsubstituted sulfates:(RO)S(═O)₂O; substituted or unsubstituted acyl units RCO₂, for example,acetate CH₃CO₂, proprionate, CH₃CH₂CO₂, butyrate CH₃CH₂CH₂CO₂, andbenzylate, C₆H₅CO₂; substituted or unsubstituted phosphates:(RO)₂P(═O)O; substituted or unsubstituted carboxylates: (RO)C(═O)O;substituted or unsubstituted azolates wherein the azolate can besubstituted on a carbon atom by a unit chosen from cyano, nitro, andamino. R can be an organic, inorganic, or organometallic group.Non-limiting examples of R include hydrogen; substituted orunsubstituted linear branched, and cyclic alkyl; substituted orunsubstituted linear, branched, and cyclic alkoxy; substituted orunsubstituted aryl; substituted or unsubstituted aryloxy; substituted orunsubstituted heterocyclic; substituted or unsubstituted heteroaryl;acyl; silyl; boryl; phosphino; amino; thio; and seleno.

In an embodiment, ionic liquids suitable for use include, but are notlimited to, one or more of imidazolium ionic liquids, pyridinium ionicliquids, tetra alkyl ammonium ionic liquids, and phosphonium ionicliquids. More than one ionic liquid may be used. Imidazolium,pyridinium, and ammonium ionic liquids have a cation comprising at leastone nitrogen atom. Phosphonium ionic liquids have a cation comprising atleast one phosphorus atom. In an embodiment, the ionic liquid comprisesa cation selected from alkyl imidazolium, di-alkyl imidazolium, andcombinations thereof. In another embodiment, the ionic liquid comprisesan anion selected from halides, acetate, carboxylates, and combinationsthereof. The ionic liquid may comprise at least one of 1-butyl 3-methylimidazolium acetate (BMImOAc), 1-butyl 3-methyl imidazolium bromide(BMImBr), 1-hexyl 3-methyl imidazolium acetate (C6MImOAc), and 1-hexyl3-methyl imidazolium bromide (C6MImBr).

The ionic liquid can be provided, or it can be generated in situ fromappropriate precursors, or both. If it is generated in situ, the solventcomprises precursors of one or more ionic liquids. The ionic liquidprecursors comprise a cation precursor, such as an alkyl imidazole,alkyl pyridine, alkyl amine, alkyl phosphine, and the like, and an anionprecursor, such as alkyl or aryl halides or acetates. In an embodiment,the precursors are methyl imidazole and butyl bromide.

The mode of introducing the ionic liquid precursors may vary dependingon the nature of the alkyl aromatics being oxidized and the nature andpurity of the product desired. In one mode of addition, the cationprecursors and the anion precursors (generally liquids at roomtemperature and pressure) are mixed with a carboxylic acid (for example,acetic acid) solvent and introduced into the oxidation reactor(s). Inanother mode of addition, the ionic liquid precursors may be mixed withthe alkyl aromatic feed and introduced into the oxidation reactors. Inanother mode of addition, both cation and anion ionic liquid precursorcomponents may be introduced into the bottom of the reactor withoutpre-mixing with any other oxidation reactor components such as the feed,carboxylic acid solvent, and catalyst package.

The solvent can also comprise a carboxylic acid. When carboxylic acidsare used in the solvent, the amount of carboxylic acid is decreasedcompared with conventional processes in order to avoid excessive solventvolumes. The carboxylic acid desirably has from 1 to 7 carbon atoms. Inan embodiment, the carboxylic acid comprises acetic acid. The solventmay contain more than one carboxylic acid. For example, the solvent mayfurther comprise benzoic acid. In another embodiment, the carboxylicacid of the solvent is acetic acid.

In an embodiment, the solvent has a ratio of the carboxylic acid to theionic liquid within a range of about 1:16 to 16:1 by weight, or about1:10 to 10:1, or about 1:9 to 9:1 by weight, or about 3:17 to 17:3 byweight, or about 1:4 to 4:1 by weight, or about 1:3 to 3:1 by weight, orabout 3:7 to 7:3 by weight, or about 7:13 to 13:7 by weight, or about2:3 to 3:2 by weight, or about 9:11 to 11:9 by weight, or about 1:1 byweight. The amount of ionic liquid includes ionic liquid precursors, ifpresent. The optional ionic solid or material capable of forming anionic salt in solution discussed below, if present, is included in theamount of ionic liquid.

Optionally, an ionic solid, such as ammonium acetate (NH₄OAc) and/orammonium bromide (NH₄Br), can be added to the mixture. Alternatively, amaterial which is capable of forming an ionic salt in solution can beadded. The material can form the ionic salt in solution by combiningwith ions present in the solution. For example, in a solution containingbromide (for example in the form of HBr) or acetate ions (for example,in the form of acetic acid), ammonia could combine with the bromide oracetate ions forming ammonium bromide or ammonium acetate. The use ofone or more ionic solids or materials capable of forming an ionic saltin solution provided an additional reduction in the level of impurities.

In an embodiment, the amount of ionic solid and material capable offorming an ionic salt in solution ranges from about 5 wt % to about 45wt %, relative to the weight of the solvent, or from about 10 wt % toabout 45 wt %, relative to the weight of the solvent. The solventincludes the carboxylic acid, the ionic liquid and/or ionic liquidprecursors, the optional ionic solid or material capable of forming anionic salt in solution, the optional water.

Optionally, the solvent may further comprise water. The water may beadded to the mixture or generated in the mixture during the oxidationprocess.

In an embodiment, the ratio of solvent to alkyl-aromatic compound in themixture ranges from about 1:1 to about 10:1 by weight, or from about1.5:1 to about 6:1 by weight, or from about 2:1 to about 4:1 by weight.The solvent includes the carboxylic acid, the ionic liquid and/or ionicliquid precursor, the optional ionic solid or material capable offorming an ionic salt in solution, the optional water.

The catalyst comprises at least one of cobalt, manganese, titanium,chromium, copper, nickel, vanadium, iron, molybdenum, tin, cerium andzirconium. In an embodiment, the catalyst comprises cobalt andmanganese. The metal may be in the form of an inorganic or organic salt.For example, the metal catalyst may be in the form of a carboxylic acidsalt, such as, a metal acetate and hydrates thereof. Exemplary catalystsinclude cobalt (II) acetate tetrahydrate and manganese (II) acetate,individually or in combination. In an embodiment, the amount ofmanganese (II) acetate is less than the amount of cobalt (II) acetatetetrahydrate by weight.

The amount of catalyst used in the invention may vary widely. Forexample, the amount of cobalt may range from about 0.001 wt % to about 2wt % relative to the weight of the solvent. In an embodiment, the amountof cobalt ranges from about 0.05 wt % to about 2 wt % relative to theweight of the solvent. The amount of manganese may range from about0.001 wt % to about 2 wt % relative to the weight of the solvent. In anembodiment, the amount of manganese ranges from about 0.05 wt % to about2 wt % relative to the weight of the solvent. In another embodiment, theratio of cobalt to manganese ranges from about 3:1 to about 1:2 byweight on an elemental metal basis.

Bromine sources are generally recognized in the art as being catalystpromoters and include bromine, ionic bromine, e.g. HBr, NaBr, KBr,NH₄Br; and/or organic bromides which are known to provide bromide ionsat the oxidation conditions, such as, benzylbromide, mono anddi-bromoacetic acid, bromoacetyl bromide, tetrabromoethane, ethylenedi-bromide. In an embodiment, the bromine source comprises or consistsessentially of or consists of hydrogen bromide. The amount of hydrogenbromide may range from about 0.01 wt % to about 5 wt %, relative to theweight of the solvent. In another embodiment, the amount of hydrogenbromide ranges from about 0.05 wt % to about 2 wt %, relative to theweight of the solvent. The solvent includes the carboxylic acid, theionic liquid, the ionic liquid precursors, the optional ionic solid ormaterial capable of forming an ionic salt in solution, the optionalwater.

Suitable oxidizing agents for the process provide a source of oxygenatoms to oxidize the p-xylene and/or p-toluic acid, and/or anotherintermediate oxidization product at the oxidation conditions employed.Examples of oxidizing agents include peroxides, superoxides, andnitrogen compounds containing oxygen such as nitric acids. In anembodiment, the oxidizing agent is a gas comprising oxygen, e.g. air,carbon dioxide, and molecular oxygen. The gas may be a mixture of gases.The amount of oxygen used in the process is preferably in excess of thestoichiometric amount required for the desired oxidation process. In anembodiment, the amount of oxygen contacted with the mixture ranges fromabout 1.2 times the stoichiometric amount to about 100 times thestoichiometric amount. Optionally, the amount of oxygen contacted withthe mixture may range from about 2 times the stoichiometric amount toabout 30 times the stoichiometric amount.

At least a portion of the components provides a liquid phase, althoughdissolution of one or more of the mixture components may not be completeat any or some time during the process. The liquid phase may be formedby mixing the components at ambient conditions. In another embodiment,the liquid phase is formed as the temperature of the mixture is raised,e.g., to about 100° C. to about 240° C. A mixture of the components maybe formed prior to the oxidation step, in the same or different vesselas that used in the oxidation step. In another embodiment, a mixture ofthe components is formed in an oxidation reactor, e.g. adding variousstreams of the components individually and/or in combination to acontinuous or semi-continuous oxidation reactor. The combined componentsand/or various streams of the components may be heated before they aremixed together or mixed before they are heated, as desired.

Though many conventional alkyl aromatic oxidation processes aretypically conducted in a mixed phase, and often include three phases(e.g. solid, gas, and liquid), they are frequently referred to in theart as “liquid phase” oxidation processes because the oxidationconditions are maintained to provide at least a portion of the mixturein the liquid phase. It is also known in the art that the number ofphases present may vary over time during the process. Processesaccording to the instant invention may also be conducted in a liquidphase or mixed phase in a similar manner as known in the art.

Conventional, liquid phase oxidation reactors as known in the art may beused to practice the invention. Examples include vessels, which may haveone or more mechanical agitators, and various bubble column reactorssuch as those described in U.S. Pat. No. 7,692,036. It is also known todesign, operate, and control such reactors and the oxidation reactionfor the oxidation conditions employed including, e.g., the temperature,pressure, liquid and gas volumes, and corrosive nature of the liquid andgas phases where applicable. See, e.g. U.S. Pat. No. 7,692,036 and U.S.Pat. No. 6,137,001.

The contacting step[s] can take place under oxidizing conditions, ifdesired. Suitable oxidizing conditions generally include a temperatureranging from about 25° C. to about 275° C. and a pressure ranging fromabout atmospheric, i.e. 0 MPa(g), to about 6 MPa(g) and a residence timeranging from about 5 seconds to about 2 weeks. That is, the mixture hasa temperature and a pressure within these ranges and may be maintainedwithin these ranges for a period of time within the residence timerange. In another embodiment, the temperature ranges from about 180° C.to about 240° C. In an embodiment, the pressure ranges from about 1.2MPa(g) to about 6.0 MPa(g); and the pressure may range from about 1.4MPa(g) to about 6.0 MPa(g). The pressure is variable and can be used tocontrol the temperature in some embodiment. In a further embodiment, theresidence time ranges from about 10 minutes to about 12 hours. Theoxidation temperature, pressure and residence time may vary based on avariety of factors including for example, the reactor configuration,size, and whether the process is, batch, continuous, or semi-continuous.An oxidation condition may also vary based on other oxidationconditions. For example, use of a particular temperature range mayenable use of a different residence time range.

In an embodiment, the terephthalic acid produced by the instantinvention may precipitate, crystallize, or solidify in a liquid phasemixture at the oxidation conditions and/or as the mixture cools. Thus, amixture according to the invention may further comprise solidterephthalic acid. Other compounds, including color bodies, and otheroxidation products may solidify with or be trapped in the solidoxidation product thus reducing the purity of the desired product. In anembodiment, the mixture comprises a liquid phase. The mixture maycomprise a gas phase such as when the oxidizing agent is added as a gas.The mixture may comprise a solid phase e.g. a mixture component, anoxidation product, or a by-product fails to dissolve or solidifies inthe mixture. In an embodiment, the mixture comprises a liquid phase, asolid phase and optionally a gas phase. In another embodiment, themixture comprises a liquid phase and a gas phase.

As noted above and discussed below, it has been discovered that theinvention may be used to produce an oxidation product having differentamounts of contaminants relative to those observed in conventionalprocesses. In addition, the invention provides new ways to control thelevel of various contaminants in the oxidation product. In anembodiment, a process according to the invention further comprisesforming the oxidation product as a solid, optionally at the oxidizingconditions, to produce the solid oxidation product and a mother liquor.The solid oxidation product may be separated from the mother liquor,i.e. liquid phase, and the mother liquor of the process may be recycledand reused in the contacting step or other steps of the processdescribed below.

Processes according to the invention may comprise one or more additionaloptional oxidizing steps. In an embodiment, a second oxidation stepincludes a second oxidizing temperature that is lower than thetemperature of the first oxidizing step. Processes according to theinvention may include additional contacting steps of the invention asdescribed herein, and/or the invention may be combined with otheroxidizing steps such as conventional oxidizing steps known in the art.Multiple contacting and/or oxidation steps may be conducted in seriesand/or parallel and may be combined with other process steps such aspurification steps described herein.

In another embodiment, the invention further comprises purifying theoxidation product. Purifying may comprise one or more additional stepsto isolate and purify the oxidation product. Examples of purifying stepsinclude: separating wherein the oxidation product is separated from themother liquor or another liquid phase such as by filtration and/orcentrifugation; washing wherein the oxidation product is washed, forexample with water and/or another solvent component; drying theoxidation product; and hydrogenation processes. Although hydrogenationprocesses can be used for purification, they are less desirable thanother purification methods due to the cost. Such additional processingsteps have been described in the general literature and are well knownto those of ordinary skill in the art to be used in various combinationsto purify oxidation products of the invention. See for example, thereferences cited in this application and the art cited therein.

A purification step of the instant invention may further comprise one ormore solvent contacting steps. A solvent contacting step comprisescontacting an oxidation product, also including washed or dried solidoxidation products, with a third solvent comprising at least one ofwater, a carboxylic acid, an ionic liquid and/or ionic liquid precursor,and a mother liquor to produce a purified oxidation product. In anembodiment, the solvent of the solvent contacting step contains ionicliquid and carboxylic acid, and optionally mother liquor. Thecomposition of the solvent for the solvent contacting step can be asdescribed above for the contacting step.

Solvent contacting may leach impurities from the solid oxidationproduct, and/or the oxidation product may be partially or completelydissolved in the solvent. Solvent contacting conditions include asolvent contacting temperature. The solvent contacting temperature maybe lower than the oxidation temperature. In an embodiment, the solventcontacting temperature is at least 20° C. lower than the oxidationtemperature. Solvent contacting may be practiced for example in the oneor more crystallizers that follow the oxidation reactor in someconventional processes. The oxidation product may solidify, precipitate,or crystallize in the solvent of the solvent contacting step.

The product made by the process, either initially or following one ormore additional oxidizing and/or purification steps, can contain lessthan about 2500 ppm 4-CBA, or less than about 2000 ppm 4-CBA, or lessthan about 1500 ppm 4-CBA, or less than about 1000 ppm 4-CBA, or lessthan about 750 ppm 4-CBA, or less than about 500 ppm 4-CBA, or less thanabout 250 ppm 4-CBA, or less than about 100 ppm 4-CBA, or less thanabout 50 ppm 4-CBA, or less than about 25 ppm 4-CBA.

While at least one exemplary embodiment has been presented in theforegoing detailed description of the invention, it should beappreciated that a vast number of variations exist. It should also beappreciated that the exemplary embodiment or exemplary embodiments areonly examples, and are not intended to limit the scope, applicability,or configuration of the invention in any way. Rather, the foregoingdetailed description will provide those skilled in the art with aconvenient road map for implementing an exemplary embodiment of theinvention. It being understood that various changes may be made in thefunction and arrangement of elements described in an exemplaryembodiment without departing from the scope of the invention as setforth in the appended claims.

What is claimed is:
 1. A process for oxidizing an alkyl-aromaticcompound comprising: contacting the alkyl-aromatic compound, a solventcomprising an ionic liquid, a bromine source, a catalyst, and anoxidizing agent in a first reaction zone to produce a first productcomprising a first mother liquor and at least one of an aromaticalcohol, an aromatic aldehyde, an aromatic ketone, and an aromaticcarboxylic acid; and adding at least a portion of the first motherliquor to the first reactor; wherein a cation of the ionic liquid isformed from a compound selected from imidazoles, pyrazoles, thiazoles,isothiazoles, azathiozoles, oxothiazoles, oxazines, oxazolines,oxazaboroles, dithiozoles, triazoles, selenozoles, oxaphospholes,pyrroles, boroles, furans, thiphenes, phospholes, pentazoles, indoles,indolines, oxazoles, isothirazoles, tetrazoles, benzofuran,dibenzofurans, benzothiophenes, dibenzothoiphenes, thiadiazoles,pyrdines, pyrimidines, pyrazines, pyridazines, piperazines, piperidines,morpholines, pyrans, annolines, phthalazines, quinazolines,quinoxalines, or combinations thereof; and wherein an anion of the ionicliquid is halides, borides, phosphates, arsenates, stibates, acetate,carboxylates, azolates, sulfates, acyl units, CO₃ ²⁻; NO₂ ¹⁻, NO₃ ¹⁻,SO₄ ²⁻,PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinations thereof, or derivativesthereof.
 2. A process for oxidizing an alkyl-aromatic compoundcomprising: contacting the alkyl-aromatic compound, a solvent comprisingan ionic liquid, a bromine source, a catalyst, and an oxidizing agent ina first reaction zone to produce a first product comprising a firstmother liquor and at least one of an aromatic alcohol, an aromaticaldehyde, an aromatic ketone, and an aromatic carboxylic acid; andcontacting at least a portion of the first product, a second solventcomprising a second ionic liquid, a second bromine source, a secondcatalyst, and a second oxidizing agent in a second reaction zone toproduce a second product comprising a second mother liquor and at leastone of the aromatic aromatic alcohol, the aromatic aldehyde, thearomatic ketone, and the aromatic carboxylic acid wherein a cation ofthe ionic liquid is formed from a compound selected from imidazoles,pyrazoles, thiazoles, isothiazoles, azathiozoles, oxothiazoles,oxazines, oxazolines, oxazaboroles, dithiozoles, triazoles, selenozoles,oxaphospholes, pyrroles, boroles, furans, thiphenes, phospholes,pentazoles, indoles, indolines, oxazoles, isothirazoles, tetrazoles,benzofuran, dibenzofurans, benzothiophenes, dibenzothoiphenes,thiadiazoles, pyrdines, pyrimidines, pyrazines, pyridazines,piperazines, piperidines, morpholines, pyrans, annolines, phthalazines,quinazolines, quinoxalines, or combinations thereof; and wherein ananion of the ionic liquid is halides, borides, phosphates, arsenates,stibates, acetate, carboxylates, azolates, sulfates, acyl units, CO₃ ²⁻;NO₂ ¹⁻, NO₃ ¹⁻,SO₄ ²⁻,PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinations thereof, orderivatives thereof.
 3. The process of claim 2, further comprising:adding at least a portion of the second mother liquor to one or both ofthe contacting steps.
 4. A process for oxidizing an alkyl-aromaticcompound comprising: contacting the alkyl-aromatic compound, a solventcomprising an ionic liquid, a bromine source, a catalyst, and anoxidizing agent in a first reaction zone to produce a first productcomprising a first mother liquor and at least one of an aromaticalcohol, an aromatic aldehyde, an aromatic ketone, and an aromaticcarboxylic acid crystallizing at least a portion of the at least one ofaromatic aromatic alcohol, the aromatic aldehyde, the aromatic ketone,and the aromatic carboxylic acid wherein a cation of the ionic liquid isformed from a compound selected from imidazoles, pyrazoles, thiazoles,isothiazoles, azathiozoles, oxothiazoles, oxazines, oxazolines,oxazaboroles, dithiozoles, triazoles, selenozoles, oxaphospholes,pyrroles, boroles, furans, thiphenes, phospholes, pentazoles, indoles,indolines, oxazoles, isothirazoles, tetrazoles, benzofuran,dibenzofurans, benzothiophenes, dibenzothoiphenes, thiadiazoles,pyrdines, pyrimidines, pyrazines, pyridazines, piperazines, piperidines,morpholines, pyrans, annolines, phthalazines, quinazolines,quinoxalines, or combinations thereof; and wherein an anion of the ionicliquid is halides, borides, phosphates, arsenates, stibates, acetate,carboxylates, azolates, sulfates, acyl units, CO₃ ²⁻; NO₂ ¹, NO₃ ¹⁻, SO₄²⁻, PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinations thereof, or derivatives thereof.5. The process of claim 3, further comprising: separating the secondmother liquor from the crystallized at least one of aromatic aromaticalcohol, the aromatic aldehyde, the aromatic ketone, and the aromaticcarboxylic acid.
 6. A process for oxidizing an alkyl-aromatic compoundcomprising: contacting the alkyl-aromatic compound, a solvent comprisingan ionic liquid, a bromine source, a catalyst, and an oxidizing agent ina first reaction zone to produce a first product comprising a firstmother liquor and at least one of an aromatic alcohol, an aromaticaldehyde, an aromatic ketone, and an aromatic carboxylic acid; wherein acation of the ionic liquid is formed from a compound selected fromimidazoles, pyrazoles, thiazoles, isothiazoles, azathiozoles,oxothiazoles, oxazines, oxazolines, oxazaboroles, dithiozoles,triazoles, selenozoles, oxaphospholes, pyrroles, boroles, furans,thiphenes, phospholes, pentazoles, indoles, indolines, oxazoles,isothirazoles, tetrazoles, benzofuran, dibenzofurans, benzothiophenes,dibenzothoiphenes, thiadiazoles, pyrdines, pyrimidines, pyrazines,pyridazines, piperazines, piperidines, morpholines, pyrans, annolines,phthalazines, quinazolines, quinoxalines, or combinations thereof; andwherein an anion of the ionic liquid is halides, borides, phosphates,arsenates, stibates, acetate, carboxylates, azolates, sulfates, acylunits, CO₃ ²⁻; NO₂ ¹⁻, NO₂ ¹⁻, NO₃ ¹ ⁻, SO₄ ²⁻,PO₄ ³⁻, (CF₃)SO₃ ¹,combinations thereof, or derivatives thereof.
 7. A process for oxidizingan alkyl-aromatic compound comprising: contacting the alkyl-aromaticcompound, a solvent comprising an ionic liquid, a bromine source, acatalyst, and an oxidizing agent in a first reaction zone to produce afirst product comprising a first mother liquor and at least one of anaromatic alcohol, an aromatic aldehyde, an aromatic ketone, and anaromatic carboxylic acid; and wherein the solvent comprises a carboxylicacid and the solvent has a ratio of the carboxylic acid to the ionicliquid within a range of about 1:10 to about 10:1 by weight wherein acation of the ionic liquid is formed from a compound selected fromimidazoles, pyrazoles, thiazoles, isothiazoles, azathiozoles,oxothiazoles, oxazines, oxazolines, oxazaboroles, dithiozoles,triazoles, selenozoles, oxaphospholes, pyrroles, boroles, furans,thiphenes, phospholes, pentazoles, indoles, indolines, oxazoles,isothirazoles, tetrazoles, benzofuran, dibenzofurans, benzothiophenes,dibenzothoiphenes, thiadiazoles, pyrdines, pyrimidines, pyrazines,pyridazines, piperazines, piperidines, morpholines, pyrans, annolines,phthalazines, quinazolines, quinoxalines, or combinations thereof; andwherein an anion of the ionic liquid is halides, borides, phosphates,arsenates, stibates, acetate, carboxylates, azolates, sulfates, acylunits CO₃ ²⁻; NO₂ ¹⁻, NO₃ ¹⁻,SO₄ ²⁻,PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinationsthereof, or derivatives thereof.
 8. The process of claim 6, wherein thecontacting step is performed under oxidation conditions.
 9. The processof claim 8, wherein the oxidizing conditions comprise a temperatureranging from about 25° C. to about 275° C. and a pressure ranging fromabout 0 MPa(g) to about 6 MPa(g).
 10. The process of claim 6, whereinthe catalyst comprises at least one of cobalt, titanium, manganese,chromium, copper, nickel, vanadium, iron, molybdenum, tin, cerium, orzirconium.
 11. The process of claim 6, wherein the solvent furthercomprises a carboxylic acid.
 12. A process for oxidizing analkyl-aromatic compound comprising: contacting the alkyl-aromaticcompound, a solvent comprising an ionic liquid, a bromine source, acatalyst, and an oxidizing agent in a first reaction zone to produce afirst product comprising a first mother liquor and at least one of anaromatic alcohol, an aromatic aldehyde, an aromatic ketone, and anaromatic carboxylic acid; and purifying the at least one of the aromaticalcohol, the aromatic aldehyde, the aromatic ketone, and the aromaticcarboxylic acid wherein a cation of the ionic liquid is formed from acompound selected from imidazoles, pyrazoles, thiazoles, isothiazoles,azathiozoles, oxothiazoles, oxazines, oxazolines, oxazaboroles,dithiozoles, triazoles, selenozoles, oxaphospholes, pyrroles, boroles,furans, thiphenes, phospholes, pentazoles, indoles, indolines, oxazoles,isothirazoles, tetrazoles, benzofuran, dibenzofurans, benzothiophenes,dibenzothoiphenes, thiadiazoles, pyrdines, pyrimidines, pyrazines,pyridazines, piperazines, piperidines, morpholines, pyrans, annolines,phthalazines, quinazolines, quinoxalines, or combinations thereof; andwherein an anion of the ionic liquid is halides, borides, phosphates,arsenates, stibates, acetate, carboxylates, azolates, sulfates, acylunits, CO₃ ²⁻; NO₂ ¹⁻,NO₃ ¹⁻, SO₄ ²⁻,PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinationsthereof, or derivatives thereof.
 13. The process of claim 12, whereinpurifying the at least one of the aromatic alcohol, the aromaticaldehyde, the aromatic ketone, and the aromatic carboxylic acidcomprises contacting at least a portion of at least one of the aromaticalcohol, the aromatic aldehyde, the aromatic ketone, and the aromaticcarboxylic acid with a third solvent comprising an ionic liquid.
 14. Aprocess for oxidizing an alkyl-aromatic compound comprising: contactingthe alkyl-aromatic compound, a solvent comprising an ionic liquid, abromine source, a catalyst, and an oxidizing agent in a first reactionzone to produce a first product comprising a first mother liquor and atleast one of an aromatic alcohol, an aromatic aldehyde, an aromaticketone, and an aromatic carboxylic acid; wherein the oxidation productcontains less than about 2500 ppm of 4-carboxybenzaldehyde wherein acation of the ionic liquid is formed from a compound selected fromimidazoles, pyrazoles, thiazoles, isothiazoles, azathiozoles,oxothiazoles, oxazines, oxazolines, oxazaboroles, dithiozoles,triazoles, selenozoles, oxaphospholes, pyrroles, boroles, furans,thiphenes, phospholes, pentazoles, indoles, indolines, oxazoles,isothirazoles, tetrazoles, benzofuran, dibenzofurans, benzothiophenes,dibenzothoiphenes, thiadiazoles, pyrdines, pyrimidines, pyrazines,pyridazines, piperazines, piperidines, morpholines, pyrans, annolines,phthalazines, quinazolines, quinoxalines, or combinations thereof; andwherein an anion of the ionic liquid is halides, borides, phosphates,arsenates, stibates, acetate, carboxylates, azolates, sulfates, acylunits, CO₃ ²⁻; NO₂ ¹⁻, NO₃ ¹⁻, SO₄ ²⁻, PO₄ ³⁻, (CF₃)SO₃ ¹⁻,combinationsthereof, or derivatives thereof.
 15. A process for oxidizing analkyl-aromatic compound comprising: contacting the alkyl-aromaticcompound, a solvent comprising an ionic liquid, a bromine source, acatalyst, and an oxidizing agent in a first reaction zone to produce afirst product comprising a first mother liquor and at least one of anaromatic alcohol, an aromatic aldehyde, an aromatic ketone, and anaromatic carboxylic acid; wherein the oxidation product contains lessthan about 500 ppm of 4-carboxybenzaldehyde wherein a cation of theionic liquid is formed from a compound selected from imidazoles,pyrazoles, thiazoles, isothiazoles, azathiozoles, oxothiazoles,oxazines, oxazolines, oxazaboroles, dithiozoles, triazoles, selenozoles,oxaphospholes, pyrroles, boroles, furans, thiphenes, phospholes,pentazoles, indoles, indolines, oxazoles, isothirazoles, tetrazoles,benzofuran, dibenzofurans, benzothiophenes, dibenzothoiphenes,thiadiazoles, pyrdines, pyrimidines, pyrazines, pyridazines,piperazines, piperidines, morpholines, pyrans, annolines, phthalazines,quinazolines, quinoxalines, or combinations thereof; and wherein ananion of the ionic liquid is halides, borides, phosphates, arsenates,stibates, acetate, carboxylates, azolates, sulfates, acyl units, CO₃ ²⁻;NO₂ ¹⁻, NO₃ ¹⁻,SO₄ ²⁻,PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinations thereof, orderivatives thereof.
 16. A process for oxidizing an alkyl-aromaticcompound comprising: contacting the alkyl-aromatic compound, a solventcomprising an ionic liquid, a bromine source, a catalyst, and anoxidizing agent in a first reaction zone to produce a first productcomprising a first mother liquor and at least one of an aromaticalcohol, an aromatic aldehyde, an aromatic ketone, and an aromaticcarboxylic acid; wherein the contacting step further comprises adding anionic solid or a material capable of forming an ionic salt wherein acation of the ionic liquid is formed from a compound selected fromimidazoles, pyrazoles, thiazoles, isothiazoles, azathiozoles,oxothiazoles, oxazines, oxazolines, oxazaboroles, dithiozoles,triazoles, selenozoles, oxaphospholes, pyrroles, boroles, furans,thiphenes, phospholes, pentazoles, indoles, indolines, oxazoles,isothirazoles, tetrazoles, benzofuran, dibenzofurans, benzothiophenes,dibenzothoiphenes, thiadiazoles, pyrdines, pyrimidines, pyrazines,pyridazines, piperazines, piperidines, morpholines, pyrans, annolines,phthalazines, quinazolines, quinoxalines, or combinations thereof; andwherein an anion of the ionic liquid is halides, borides, phosphates,arsenates, stibates, acetate, carboxylates, azolates, sulfates, acylunits, CO₃ ²⁻; NO₂ ¹ , NO₃ ¹⁻, SO₄ ²⁻, PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinationsthereof, or derivatives thereof.
 17. A process for oxidizing analkyl-aromatic compound comprising: contacting the alkyl-aromaticcompound, a solvent comprising an ionic liquid, a bromine source, acatalyst, and an oxidizing agent in a first reaction zone to produce afirst product comprising a first mother liquor and at least one of anaromatic alcohol, an aromatic aldehyde, an aromatic ketone, and anaromatic carboxylic acid; and crystallizing at least a portion of the atleast one of aromatic aromatic alcohol, the aromatic aldehyde, thearomatic ketone, and the aromatic carboxylic acid wherein a cation ofthe ionic liquid is formed from a compound selected from imidazoles,pyrazoles, thiazoles, isothiazoles, azathiozoles, oxothiazoles,oxazines, oxazolines, oxazaboroles, dithiozoles, triazoles, selenozoles,oxaphospholes, pyrroles, boroles, furans, thiphenes, phospholes,pentazoles, indoles, indolines, oxazoles, isothirazoles, tetrazoles,benzofuran, dibenzofurans, benzothiophenes, dibenzothoiphenes,thiadiazoles, pyrdines, pyrimidines, pyrazines, pyridazines,piperazines, piperidines, morpholines, pyrans, annolines, phthalazines,quinazolines, quinoxalines, or combinations thereof; and wherein ananion of the ionic liquid is halides, borides, phosphates, arsenates,stibates, acetate, carboxylates, azolates, sulfates, acyl units, CO₃ ²⁻;NO₂ ¹⁻, NO₃ ¹⁻,SO₄ ²⁻, PO₄ ³⁻, (CF₃)SO₃ ¹⁻, combinations thereof, orderivatives thereof.
 18. The process of claim 17, further comprising:adding at least a portion of the first mother liquor to the firstreactor.